Selectively adjustable junction box

ABSTRACT

An adjustable junction box is provided that allows a technician to selectively adjust the distance between an outer surface of the junction box and an outer surface of a stud to which the junction box is interconnected. A selectively-removable cover is also provided that allows an outlet, for example, to be interconnected to a power supply and later removed for inspection.

This application claims the benefit of U.S. Provisional PatentApplication No. 62/667,752, filed May 7, 2018, the entirety of which isincorporated by reference herein.

FIELD OF THE INVENTION

Embodiments of the present invention are generally directed to ajunction box that accommodates an electrical device such as an outlet,switch, media connector, telecommunications connector, etc. Theelectrical device is interconnected to a selectively removable coverassociated with an outer opening of the junction box. The junction boxof one embodiment of the present invention is adjustable relative to awall to which the junction box is installed.

BACKGROUND OF THE INVENTION

Electrical wires connected to electrical devices (i.e., outlets andswitches) found in dwellings and office buildings terminate or meet injunction boxes. Junction box location is strictly controlled by buildingcodes. The number and quality of wires extending into a junction box isalso verified by building inspectors.

Normal installation entails interconnecting the junction box to a woodenor metal stud. Wires are then brought to the junction box and capped. A“rough-in” inspection is often performed next where the inspectorverifies proper junction box location and the presence of wiresrequired.

Eventually an internal building surface, i.e., drywall, is added to thestud. As one of ordinary skill in the art will appreciate, this processis messy and drywall joint compound, which is often referred to as“mud,” often enters the junction box. Drywall mud can contact wires and,as it hardens, will cause the wires to lose resiliency which makes itdifficult to later install the electrical device. The wire ends can alsobe compromised, wherein cleaning or trimming may be required so thatthey can interface with the electrical device. Furthermore, junctionboxes usually include bosses that accommodate screws used tointerconnect the electrical device to the junction box. The bosses canalso be filled with mud, thereby making it difficult to laterinterconnect the outlet or switch.

After installation, the edge of the junction box may not be flush withthe internal building surface, which may make it difficult to installfinish plates onto the electrical device. Those of ordinary skill in theart will also appreciate that alignment mismatches often require longerfasteners, which often do not come with the finish plates, to connectthe electrical device to the junction box. If the junction box extendspast the interior building surface, there may be a gap between the edgeof the interior building surface and the finish plate which is notaesthetic and must be addressed.

After these common installation issues are addressed, the electricaldevice is interconnected to the junction box and the inspector will beinvited to re-inspect the electrical system to ensure all outlets andswitches work properly.

Accordingly, it is a long felt need to provide a junction box thatfacilitates interconnection of the electric device, allows realignmentrelative to the building surface if required, expedites installation,and expedites inspection.

SUMMARY OF THE INVENTION

It is one aspect of some embodiments of the present invention to providea junction box with a removable cover. The cover is selectivelyinterconnected to the junction box, which may be fixedly or adjustablyinterconnected to a wall stud. The cover receives and secures anelectrical device so that it can be removed from the junction box withthe cover if necessary. This feature allows for the majority ofelectrical outlet/switch insulation to occur at the rough-in stage(i.e., a one-step installation procedure), which drastically reducesoverall installation time. The cover can be easily removed from thejunction box to allow the inspector to review the integrity of theelectrical interconnections. A shield may be placed over the outlet orswitch to prevent common construction debris from damaging theelectrical device. After power is delivered to the outlet or switch, theinspector will again test the functionality of the electronic component.A faceplate is installed before or after final inspection to completeinstallation. This aspect of one embodiment of the present invention,thus, removes one step from the installation process.

In one embodiment of the present invention, the cover includesprotrusions or arms that end in fingers that selectively interconnect tothe junction box. The fingers may selectively engage openings in anupper and lower portion of the junction box. One of ordinary skill inthe art will appreciate that the opening may be found on the lateralsides of the box. A passage is provided that allows one to insert a toolto selectively deflected arms, thereby removing the fingers from theopenings and allowing cover removal.

In operation, wherein the following order is not important, theelectrical device is interconnected to the cover. Next, wires areinterconnected to the electrical device and shield is interconnected toat least one of the electrical device and cover. At the rough in stage,the inspector can review the interconnection of the wires to theelectrical device as the cover can be selectively removed from thejunction box, or the outlet/cover is made to hang from the junction box.The cover is then reconnected to the junction box and internal buildingsurface, i.e., drywall, is interconnected to the studs. The cover (withinterconnected electrical device and shield, if desired) can bereinstalled on the junction box before wall painting or texturing. Thefinal step comprises interconnecting a faceplate to the outlet or switchin the traditional fashion.

It is another aspect of some embodiments of the present invention toprovide an adjustable junction box. As discussed above, often theposition of the junction box relative to the internal building serviceis not ideal, wherein the junction box must be moved into or out of thewall, a difficult and time-consuming task. This task may also requirethat portions of the drywall be removed and may elicit a furtherinspection, which is not ideal. In one embodiment, a bracket comprisedof a plate having outwardly extending abutments is interconnected to thestud. The abutments slidingly receive protrusions extending from anupper and lower surface of the junction box. Thus, the junction box issupported by the abutments, which prevents movement along the length ofthe stud. The bracket also has a plurality of grooves, slots, or otherindentations that receive a locking member operably associated with thejunction box. The locking member of one embodiment of the presentinvention is a captured worm screw with threads that selectivelyinterface with the brackets/grooves/slots. Rotating the worm screw willmove the junction box into and out of the wall.

The locking member of another embodiment of the present invention is aselectively deflectable tab that extends from the outer surface of thejunction box. In one embodiment, the member is similar to a leaf springwith the first end interconnected to an inner surface of the junctionbox and a second end that extends through the junction box that isadapted to fit within one of the grooves or slots provided by thebracket. The member can be removed from the groove/slot by deflecting itwith a tool that engages and moves the second end.

The Summary of the Invention is neither intended nor should it beconstrued as being representative of the full extent and scope of thepresent invention. That is, these and other aspects and advantages willbe apparent from the disclosure of the invention(s) described herein.Further, the above-described embodiments, aspects, objectives, andconfigurations are neither complete nor exhaustive. As will beappreciated, other embodiments of the invention are possible using,alone or in combination, one or more of the features set forth above ordescribed below. Moreover, references made herein to “the presentinvention” or aspects thereof should be understood to mean certainembodiments of the present invention and should not necessarily beconstrued as limiting all embodiments to a particular description. Thepresent invention is set forth in various levels of detail in theSummary of the Invention as well as in the attached drawings and theDetailed Description and no limitation as to the scope of the presentinvention is intended by either the inclusion or non-inclusion ofelements, components, etc. in this Summary of the Invention. Additionalaspects of the present invention will become more readily apparent fromthe Detail Description, particularly when taken together with thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate embodiments of the invention andtogether with the general description of the invention given above andthe detailed description of the drawings given below, serve to explainthe principles of these inventions.

FIG. 1 is a perspective view of the adjustable junction box system ofone embodiment of the present invention;

FIG. 2 is a right elevation view of FIG. 1;

FIG. 3 is a left elevation view of FIG. 1;

FIG. 4 is an exploded perspective view of the embodiment of the presentinvention shown in FIG. 1;

FIG. 5 is a perspective view of the embodiment of FIG. 1 shown with anoutlet interconnected thereto;

FIG. 6 is a perspective view of another embodiment of the presentinvention;

FIG. 7 is an exploded perspective view of the embodiment of the presentinvention shown in FIG. 6;

FIG. 8 is a perspective view of another embodiment of the presentinvention;

FIG. 9 is a left elevation view of FIG. 8;

FIG. 10 is a perspective view of another embodiment of the presentinvention;

FIG. 11 is a right elevation view of FIG. 8;

FIG. 12 is a perspective view of another embodiment of the presentinvention;

FIG. 13 is an exploded perspective view of the embodiment of the presentinvention shown in FIG. 12;

FIG. 14 is an exploded right elevation view of another embodiment of thepresent invention; and

FIG. 15 is a right elevation view of the embodiment of the presentinvention shown in FIG. 14.

The following component list and associated numbering found in thedrawings is provided to assist in the understanding of one embodiment ofthe present invention:

# Component 2 Adjustable junction box system 6 Worm screw 10 Junctionbox 14 Outlet 18 Channel 22 Bracket 24 Anchor point 26 Retainer 30 Upperend 34 Ledge 38 Lower end 42 Upper tab 46 Opening 50 Threads 54 Cover 58Arm 62 Finger 66 Opening 70 Upper surface 74 Lower surface 78 Aperture82 Front face 86 Passage 202 Adjustable junction box system 207 Clip 209First end 210 Junction box 213 Inner surface 217 Second end 218 Slot 221Groove 222 Bracket 226 Retainer 234 Ledge 242 Upper tab 246 Opening 254Cover 258 Arm 262 Finger 266 Opening 270 Upper surface 278 Aperture 302Adjustable junction box system 306 Standoff 309 Nut plate 310 Junctionbox 354 Cover 402 Adjustable junction box system 406 Teeth 409Protrusion 410 Junction box 454 Cover 458 Arm 502 Adjustable junctionbox system 506 Junction box housing 509 Wheel 510 Junction box 602Adjustable junction box system 606 Adjustable collar 609 Housing 611Adjustable screw 654 Cover 658 Arm 662 Finger

It should be understood that the drawings are not necessarily to scale.In certain instances, details that are not necessary for anunderstanding of the invention or that render other details difficult toperceive may have been omitted. It should be understood, of course, thatthe invention is not necessarily limited to the particular embodimentsillustrated herein.

DETAILED DESCRIPTION

FIGS. 1-5 show the adjustable junction box system 2 of one embodiment ofthe present invention that employs a captured worm screw 6. Rotation ofthe worm screw 6 inclemently moves a junction box 10 into a wall (alongthe direction of Arrow A) or out of the wall (along Arrow B). Thejunction box 10 is of a configuration similar to traditional boxes thatreceive an electrical device, in this example an outlet 14. Those ofordinary skill in the art will appreciate, however, that the junctionbox 14 may be of any size and shape and may be designed to accommodatemultiple electrical devices. The junction box 10 has a channel 18 thatmaintains the worm screw 6.

In operation, the junction box 10 is interconnected to a bracket 22having a retainer 26 at an upper end 30 and a ledge 34 at a lower end38. The retainer 26 receives an upper tab 42 extending from an uppersurface 70 of the junction box 10, and the ledge 35 receives acomplementary tab (not shown) extending from a lower surface of thejunction box 10. The interface between the tabs and the retainer/ledgeallows the junction box to move into and out the wall, but preventsmovement of the junction box along the length of the stud. The bracket22 also includes a series of openings 46 that selectively engage threads50 of the worm screw 6. In operation, rotation of the captured wormscrew 6 incrementally moves the interconnected junction box 10 into andout of the wall. Anchor points 24 on the bracket 22 are adapted toreceive screws or nails for interconnection to a stud. One of ordinaryskill in the art will appreciate that at least one of these anchorpoints 24 may be a slot or an arcuate slot that allows for selectiverotation of the bracket to address angular (i.e., non-plumb) studirregularities.

The junction box 10 selectively receives a cover 54 with upper and lowerarms 58. The arms end 58 in upper and lower fingers 62 that areselectively received within openings 66 in the upper surface 70 and thelower surface 74 of the junction box 10. Apertures 78 are provided in afront face 82 of the cover 54 that allows selective access to an end ofthe worm screw 6, which allows a technician to rotate the worm screw 6.Apertures 78 may be provided on both sides of the cover 54 such thatcover orientation relative to the junction box 10 is irrelevant.Passages 86 are provided within the cover that allow a technician toinsert a tool, such as a flathead screwdriver, into a closed junctionbox 10 to selectively deflect the fingers 62 from the openings andremove the cover 54 from the junction box 10.

FIGS. 6 and 7 show another embodiment of an adjustable junction boxsystem 202 that employs a junction box 210 that selectively interfaceswith a bracket 222. As in the embodiments described above, the junctionbox 210 in this embodiment includes an upper tab and a lower tab (notshown) that selectively engage a retainer 226 and ledge 234,respectively, provided in the bracket 222. The primary difference tothat a selectively deflectable clip 207 is provided instead of a wormscrew.

More specifically, the clip 207 is interconnected on a first end 209 toan inner surface 213 of the junction box 210. One of ordinary skill inthe art will also appreciate that the first end 209 can beinterconnected to the outer surface of the junction box. A second end217 of the clip 207 extends through a slot 218 in the outer surface ofthe junction box and is designed to flex to be received by one of theopenings 246 in the bracket 222. A small opening or groove 221 in theclip 207 may be provided, wherein an aperture 278 in aselectively-interconnectable cover 254 allows for insertion of a tool toflex the second end 217 of the clip 207 to remove it from the bracketopening 246, which allows the junction box 210 to incrementally slideinto or out of the wall. The cover of this embodiment of the presentinvention is very similar to that described above wherein arms 258 areprovided that end in fingers 262 that are selectively received inopenings 266 in the upper surface 270 and lower surface 274 of thejunction box 210.

FIGS. 8 and 9 show another embodiment of the present invention that usesa cover 354 having plurality standoffs 306 that selectively interconnectto nut plates 309 integrated into a rear surface of the junction box310. The cover 354 also is adapted to receive and secure an outlet orswitch.

FIGS. 10 and 11 show yet another embodiment of the present inventionwhere the cover 454 employs arms 458 that extends from the back surface.The arms 458 employ a plurality of teeth 406 that selectively engageprotrusions 409 provided in the upper and lower surfaces of the junctionbox 410. The arms 458 are flexed outwardly to remove the teeth 406 fromthe protrusion 409 which allows for selective adjustment or removal ofthe cover 454. That is, the cover and interconnected electrical devicecan be spaced as needed to accommodate interior surface installation.

FIGS. 12 and 13 show another embodiment of the present inventioncomprised of a junction box housing 506 that receives a junction box510. The junction box housing 506 is interconnected to a wall stud andthe junction box 510 is selectively received within the junction boxhousing 506. Here, an adjustment wheel 509 is provided that when rotatedin one direction moves the junction box 510 into the junction boxhousing 506. Rotation of the adjustment wheel 509 in the oppositedirection will urge the junction box 510 and interconnected outlet fromthe wall.

FIGS. 14 and 15 show another embodiment of the present invention thatuses an adjustable collar 606 interconnected to a junction box housing609 by a plurality of adjustable screws 611. The junction box housing609 is interconnected to a stud. Movement of the adjustment screws 611will selectively move the collar 606 into and out of the junction boxhousing 609. The collar 606 is also configured to selectively receive acover 654 that accommodates an outlet 614. The cover may include arms658 ending in fingers 662 that are received in openings in theadjustable collar 606.

While various embodiments of the present invention have been describedin detail, it is apparent that modifications and alterations of thoseembodiments will occur to those skilled in the art. It is to beexpressly understood that such modifications and alterations are withinthe scope and spirit of the present invention, as set forth in thefollowing claims. Further, it is to be understood that the invention(s)described herein is not limited in its application to the details ofconstruction and the arrangement of components set forth in thepreceding description or illustrated in the drawings. The invention iscapable of other embodiments and of being practiced or of being carriedout in various ways. Also, it is to be understood that the phraseologyand terminology used herein is for the purpose of description and shouldnot be regarded as limiting. The use of “including,” “comprising,” or“having” and variations thereof herein is meant to encompass the itemslisted thereafter and equivalents thereof as well as additional items.

What is claimed is:
 1. An adjustable junction box system, comprising: abracket adapted for interconnection to a stud, the bracket having afirst end associated with a retainer and a second end associated with aledge, the bracket also having a plurality of openings between the firstend and the second end that extend at least a portion of the distancebetween an outer edge and an inner edge of the bracket; a junction boxcomprised of a top surface, a bottom surface, a left lateral surface,and a right lateral surface, the junction box further comprising: anupper tab extending away from the top surface, the upper tab configuredto operatively interface with the retainer, a lower tab extending awayfrom the bottom surface, the lower tab configured to operativelyinterface with the ledge, a channel integrated into at least one of theleft lateral surface and the right lateral surface, a screw positionedin the channel, the screw having threads that operatively interconnectwith at least a portion of the plurality of openings; and whereinrotation of the screw in a first direction moves the junction box awayfrom the inner edge of the bracket and rotation of the screw in a seconddirection moves the junction box toward the inner edge of the bracket.2. The adjustable junction box system of claim 1, further comprising: acover configured to selectively associated with the top surface, thebottom surface, the left lateral surface, and the right lateral surface;and wherein the cover is also configured to secure an electrical device.3. The junction box of claim 2, wherein the cover includes a firstinwardly extending arm that ends in a first finger and a second inwardlyextending arm that ends in a second finger, wherein the first finger isconfigured to be received within an opening in the top surface, andwherein the second finger is configured to be received within an openingin the bottom surface, which secures the cover to the junction box.
 4. Ajunction box, comprising: a top surface; a bottom surface; a leftlateral surface; a right lateral surface; and a cover adapted to securean electrical device and configured to selectively interconnect to outeredges of the top surface, the bottom surface, the left lateral surface,and the right lateral surface.
 5. The junction box of claim 4, whereinthe cover includes a first inwardly extending arm that ends in a firstfinger and a second inwardly extending arm that ends in a second finger,wherein the first finger is configured to be received within an openingin the top surface, and wherein the second finger is configured to bereceived within an opening in the bottom surface.
 6. The junction box ofclaim 4, further comprising a first tab associated with the top surfaceand a second tab associated with the bottom surface; and a bracketadapted for interconnection to a wall stud, the bracket having an upperretainer for operative receipt of the first tab, and a lower ledge forreceipt of the second tab.
 7. The junction box of claim 6, wherein thebracket includes a plurality of openings or cavities, and furthercomprising a means for selective interconnection associated with theleft lateral surface or the right lateral surface that has a member forselective interconnection to at least one of the plurality of openingsor cavities.
 8. The junction box of claim 6, wherein the means forselective interconnection is a screw, wherein the at least one memberare threads of the screw, wherein at least one thread is configured forselective engagement within one of the plurality of openings orcavities, and wherein rotation of the screw moves the junction boxrelative to the bracket.
 9. The junction box of claim 6, wherein themeans for selective interconnection is a deflectable clip with a firstend interconnected to the left lateral surface or the right lateralsurface and a second end configured for selective engagement within oneof the plurality of openings or cavities.
 10. A junction box,comprising: a top surface; a bottom surface; a left lateral surface; aright lateral surface; a rear surface; a first protrusion associatedwith the top surface and a second protrusion associated with the bottomsurface; a bracket adapted for interconnection to a wall stud, thebracket having an upper channel for operative receipt of the firstprotrusion and a lower channel for receipt of the second protrusion; andwherein the bracket includes a plurality of receptacles, and furthercomprising a worm gear operatively associated with one of the topsurface, the bottom surface, the left lateral surface or the rightlateral surface, the worm gear having a plurality of threads, wherein atleast one thread is configured for selective engagement within one ofthe plurality of receptacles.
 11. The junction box of claim 10, furthercomprising a cover configured to selectively interconnect to outer edgesof the top surface, the bottom surface, the left lateral surface, andthe right lateral surface; and wherein the cover is adapted to secure anelectrical device.
 12. The junction box of claim 11, wherein the coverincludes a first inwardly extending arm that ends in a first finger anda second inwardly extending arm that ends in a second finger, whereinthe first finger is configured to be received within an opening in thetop surface, and wherein the second finger is configured to be receivedwithin an opening in the bottom surface, which secures the cover to thejunction box.